how to operate cbz 2002 choke system

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Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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Filed Under (Harley Davidson) by admin on 28-02-2012

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The majority of HSR42/45 installations use the Harley cable. Installation is simple when the installation instructions are followed, step by step. Those steps are: • Remove the stock Harley choke cable assembly. • Remove the spring and plunger from the stock cable. • Remove the Mikuni “Starter Nut” from the HSR. • Remove the Mikuni spring and plunger from the HSR. • Install the Mikuni spring and plunger on the Harley choke cable. • Install the Harley choke cable with the fitted Mikuni spring and plunger into the HSR carburetor. • DO NOT use the Mikuni Starter Nut; discard it. • DO NOT use the Harley spring or plunger; discard them. Note: If you do not have installation instructions, you may download them from the www.mikuni.com website in the “manuals” section. If the Mikuni Starter Nut is fitted to the Harley cable, the choke plunger is held off its seat and the choke is open all the time. If the Harley spring and plunger are used, the plunger does not seal and the choke is open all the time. The result, in both cases, is very poor fuel mileage (30 mpg or less). Another possible cause of poor mileage, rough idle and fouled spark plugs is incorrect cable routing. The stock Harley choke cable is very stiff and may not be fully seated in the metal elbow at the carburetor end of its run. This condition is easily corrected. On occasion, one of these errors may have been made by someone else at another location. The unfortunate mechanic who inherits the task of correcting the rich condition, poor idle and poor fuel mileage may have no clue as to the mismatch of parts. For this reason, we include the photos and text to help you discover if your installation is correct.

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HONDA CRF250X OWNER'S MANUAL

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Filed Under (Honda) by admin on 01-12-2010

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Always follow the proper starting procedure described below. Your motorcycle can be kickstarted wirh the transmission in gear by pulling in the clutch lever before operating the kickstarter. Preparation Make sure that the transmission is in neutral. Turn the fuel valve ON. Fuel Valve Starting Procedure Always follow the proper starting procedure described as follow. 4. Warm up the engine; don’t operate the throttle. 5. About 15 seconds after the engine startes, push the choke knob back all the way to fully OFF. If idling is unstable, open the throttle slightly. Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. High Air Temperature 35°C (95°F) or above 1. Do not use the choke. 2. Keep the throttle fully closed. 3. Start the engine following step 3 under Normal Air Temperature. Low Air Temperature 10°C (50°) or below 1. Follow steps 1-4 under Normal Air Temperature. 2. Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob is pushed back all the way to fully OFF. Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. Hot Engine Starting 1. Pull the hot start lever (3) and start the engine following step 3 under Normal Air Temperature. 2. As soon as the engine starts, release the hot start lever. NOTICE NOTICE Basic Operating Instructions 15 (1) fuel valve The three-way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor. ON -Turning the fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor. OFF -Turning the fuel valve OFF after stopping the engine prevents the flow of fuel from the fuel tank to the carburetor. RES -Turning the fuel valve to RES allows fuel to flow from the reserve fuel supply to the carburetor. (1) fuel valve (2) choke knob Check the engine oil, transmission oil and coolant levels before starting the engine (pages 44,47,48). To restart a warm engine, follow the procedure for ”High Air Temperature. ” Normal Air Temperature 10°C-35°C (50°F-95°F) 1. Pull the choke knob (2) up all the way to fully ON, if the engine is cold. 2. Keep the throttle fully closed. 3. Pull the clutch lever all the way in, and press the starter button with the throttle completely closed. Or operate the kickstarter to start the engine. Starting from the top of the stroke, kick through to the bottom with a rapid, continuous motion. Do not operate the throttle. Allowing the kickstarter to snap back freely against the pedal stop can damage the engine case.

2005 Honda CRF450X OWNER'S MANUAL AND COMPETITION HANDBOOK

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Filed Under (Honda) by admin on 04-12-2010

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Starting & Stopping the Engine Always follow the proper starting procedure described below. Your CRF can be started with the transmission in gear by pulling in the clutch lever before operating the kickstarter or start button. Preparation Make sure that the transmission is in neutral. Turn the fuel valve ON. Fuel Valve Starting Procedure Always follow the proper starting procedure described as follow. 5. Warm up the engine; don’t operate the throttle. 6. About 15 seconds after the engine starts, push the choke knob back all the way to fully OFF. If idling is unstable, open the throttle slightly. Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. HighAirTemperature 35°C (95°F) or above 1. Turn the fuel valve (1) ON. 2. Do not use the choke. 3. Keep the throttle fully closed. 4. Start the engine following step 4 under “Normal Air Temperature.” LowAirTemperature 10°C (50°) or below 1. If the temperature is below 32°F (0°C), open the throttle two or three times. (The engine requires a richer mixture for starting in cold weather. When the throttle is so opened, the accelerator pump will feed extra fuel to the cylinder, thereby facilitating starting in cold weather.) 2. Follow steps 1-5 under “Normal Air Temperature.” 3. Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob is pushed back all the way to fully OFF. Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. (cont’d) NOTICE NOTICE Basic Operating Instructions 15 (1) fuel valve The three-way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor. ON -Turning the fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor. OFF -Turning the fuel valve OFF prevents the flow of fuel from the fuel tank to the carburetor. RES -Turning the fuel valve to RES allows fuel to flow from the reserve fuel supply to the carburetor. (1) fuel valve (2) choke knob Check the engine oil, transmission oil and coolant levels before starting the engine (pages 44,47,48). To restart a warm engine, follow the procedure for”High Air Temperature.” NormalAirTemperature 10°C-35°C (50°F-95°F) 1. Turn the fuel valve (1) ON. 2. Pull the choke knob (2) fully ON, if the engine is cold. 3. Keep the throttle fully closed. 4. Pull the clutch lever all the way in, and depress the start button. Or operate the kickstarter to start the engine. Starting from the top of the stroke, kick through to the bottom with a rapid, continuous motion. Do not operate the throttle. Allowing the kickstarter to snap back freely against the pedal stop can damage the engine

2001-2002 GL1800 A ABS Speed Sensor Wire Clamp Location INSPECTION/ REPAIR PROCEDURES

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Filed Under (Honda) by admin on 29-01-2011

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1. If the VIN is within the preceeding range, inspect the front ABS speed sensor wire clamp according to the following illustrations. 2001-2002 GL1800A ABS Speed Sensor Wire Clamp Location INCORRECT Installation CORRECT Installation Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location 0112 GL1800 #9*GL1800 #9*0112*2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location*GL1800, ABS Speed Sensor Wire Clamp Location*Motorcycle*1800 2 of 2 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #9 DECEMBER 2001 IDENTIFICATION There is no identification mark associated with this Service Bulletin. PARTS INFORMATION There is no parts information associated with this Service Bulletin. WARRANTY INFORMATION The normal warranty claim submission requirements apply. Submit one warranty claim per VIN with the following information only: Inspected and REPAIRED Template: GL#9 Hours: 0.2 hours Parts: None If the clamp is installed correctly on top of the speed sensor, no further action is necessary. 3. If the clamp is installed incorrectly under the speed sensor, remove and reinstall the clamp and speed sensor correctly. Torque the bolts,. Torque: 12 N • m (1.2 kgf • m, 9 lbf • ft) If the speed sensor wire clamp for the front ABS speed sensor is installed incorrectly, the ABS speed sensor air gap may be out of specification. This does not affect ABS speed sensor operation, but the clamp should be installed correctly. Inspect and repair all affected units using the Inspection/Repair procedures listed below. Inspect all unsold units and customer units brought in for service. AFFECTED UNITS 2001-2002 GL1800A units as follows: MODEL 2001 GL1800A All units 2002 GL1800A 1HFSC474*2A100001 – 1HFSC474*2A101643 * = denotes check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection. CUSTOMER NOTIFICATION There is no customer notification associated with this Service Bulletin.

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2008 KTM 50 SX JUNIOR 50 SX OWNER'S MANUAL

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Filed Under (KTM) by admin on 22-10-2010

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Choke Dell’Orto carburetor PHVA 14 DS (50SXJunior) Choke lever [1] is mounted to the right side of the carburetor. If you move the choke lever up to the stop, a hole is opened in the carburetor through which the engine can draw in additional fuel. This results in a “rich” fuel-air mixture required for a cold start. Moving the choke lever back closes the hole in the carburetor again. Choke Dell’Orto carburetor PHBG 19 BS (50 SX) Choke control knob [2] is mounted to the left side of the carburetor. If you pull the choke control knob up to the stop and turn it 90º, a hole is opened in the carburetor through which the engine can draw additional fuel. This results in a “rich” fuel-air mixture required for a cold start. Turning back the choke control knob returns the knob to the starting position and closes the hole in the carburetor again. Kickstarter The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake lever The foot brake lever is located in front of the right footrest. The basic position can be adjusted to the seating position (see maintenance work). Side stand (50 SXJunior) Use your foot to swing the side stand forwards to the stop. Make sure it rests securely on solid ground.

HW Prowler Carburetor Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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1. Remove both seats and the plastic seat pans under the seats. 2. Remove the engine cover 3. Remove the air-box by removing the cross-bar support that runs under the air-box to the framing on each side by the seat framing and disconnect the air box from the carburetor and from the plastic intake in the rear. 4. Disconnect the engine breather hose from the bottom of the air box 5. Set the air-box to the side 6. Disconnect the plug going to the stock carburetor, this is the electronic choke. Wrap the end left on the vehicle with electrical tape. 7. Cut the fuel line just above the fitting on the passenger side of the carb 8. Remove the side cover off the drivers side of the carb where the throttle cable goes in, see fig. #1 9. Pull the throttle cable out and then remove the throttle cable end from the throttle plate See Fig. #2 10. Loosen the clamp on the rear of the carb holding the carb on 11. Pull the carb out of the intake boot 12. Set OE carb to the side. 13. Push the new Carb into the intake boot making sure the carb is perfectly vertical and then tighten the clamp back up. The new carb is slightly larger than the stock one so some additional pressure will be needed to get it in. 14. Route all the breather lines connected to the carb down under the carb. 15. Connect the throttle cable onto the new carb but putting the cable end in the bottom hole of the throttle plate on the passenger side of the carb allowing the cable to ride in the slot in the plate and then turn the throttle plate clock wise allowing the threaded end of the cable to fit into the lower round hole of the throttle cable connection plate. See Fig. #3 16. Make sure you have a nut on each side of the plate turn the nut on the outside of the plate to take up the slack in the throttle cable then tighten the nut on the inside of the plate. See Fig. #3 17. Push the fuel line onto the fuel inlet on the passenger side of the carb and install the supplied clamp to hold it on. The fuel line will be a little hard to push on. 18. DO NOT ATTEMPT TO INSTALL THE CHOKE CABLE PARTS SUPPLIED IN THE KIT UNTIL AFTER THE CHOKE CABLE ITSELF IS INSTALLED AND READY TO SCREW INTO THE CARBUETOR. 19. To install the supplied choke cable, drill a 3/8″ hole in the dash on the left side of the steering wheel in a location convenient to your left hand. 20. Remove the plastic nut from the bottom of the choke handle on the choke cable. 21. Push the choke cable thru the hole you drilled and then slide the nut over the cable to the inside of the dash and reinstall back on the back of the choke mechanism. Some dash screws maybe needed to be removed to accomplish this

2002-2003 Honda GL1800/ A Frame Weld REPAIR PROCEDURE OVERVIEW

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Filed Under (Honda) by admin on 14-12-2010

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If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. • If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510) • Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet , Welding Manual , Welding Template Box , or Frame Weld Inspection Chart , you may order them at no cost from DDS at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. Disassembly Overview You will be removing the following components from the vehicle as instructed in the Dealer Booklet : • Handlebar weights • Rear view mirrors • Swingarm pivot covers • Rider foot pegs • Seat • Side covers/Engine side covers • Fairing pockets • Fairing molding • Meter panel • Top shelter • Battery • Fuel tank • Main wiring harness ground • Front lower fairing • Front exhaust pipe protector • Muffler/exhaust pipe • Antenna Whip(s) • Coolant reserve tank • Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: You MUST cover the following with RED duct tape for welder identification pur- poses: • Negative (-) and positive (+) battery cables • Fuel return hose end • Fuel feed hose end • Main wiring harness ground • Alternator • Exhaust ports Welding Overview A qualified TIG welder will weld the frame following the procedures in the 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual . Re-assembly Overview You will be inspecting the new TIG welds, painting the frame, and re-assembling the vehicle as detailed in the Dealer Booklet and Frame Weld Inspection Chart (S0513)

2001-2002 Honda GL1800/A Frame Weld Inspection PROCEDURE

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Filed Under (Honda) by admin on 22-04-2011

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IMPORTANT: During these procedures you may be using and referring to the following materials, originally sent to you with Service Bulletin GL1800 #14. • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Procedures (S0510) • Frame Weld Inspection Chart (S0516) • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • 2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) • Welding Template Box (S0512)If you need additional copies of these materi- als you may order them at no cost from Resolve at (440) 572-0725. 1. Position the motorcycle on a firm, level surface, in an area where there is enough room to safely lay it on its left side. 2. Remove the left side mirror by following the nstructions on page 2-7 of the Service Manual. 3. Remove the left engine side cover by following the nstructions on page 2-5 of the Service Manual. 4. Remove the antenna whip(s). 5. Remove the coolant reserve tank by fol- lowing the instructions on page 6-7 of the Service Manual. 6. Place thick, non-abrasive padding (such as furniture blankets) on the ground to protect the motorcycle when you lay it on its side. 7. Lock the handlebars to the RIGHT, using the ignition key. 8. Using two people, gently lay the motor- cycle down on its LEFT side on the pad- ding. The motorcycle will first rest on the wheels and left engine and saddlebag guards. Continue to lean the motorcycle to the left until it rests on the left handlebar end and left engine and saddlebag guards. The motorcycle should be laying on the padding, with its engine guard, saddlebag guard, and handlebar end resting on the padding – no painted parts should be con- tacting the padding. 9. Clean the frame crossmember with acetone. 10. Draw a line on each side of the grinding template (S0512) 30 mm from the for- ward edge, stopping  between the two arrows, as illustrated below. 11. Put this template on the frame and, using a fine-tipped felt marker (such as a Sharpie), draw a 30 mm line on both crossmember welds. Start this line at the forward edge of the grinding template and stop between the two arrows as shown in the illustration on the next page.Now remove the grinding template

INSTRUCTIONS ON HOW TO R & R YOUR Swingarm

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Filed Under (Tips and Review) by admin on 12-12-2010

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• Upgrade Your Pre- 2002 FL Or FXR Rear Fork & Get Rid Of The Crappy & Dangerous (Cleve Blocks) & Replace Them With A Stable System. • R & R your Swing Arm, Belt Drive, Swing Arm Pivot Shaft, and Rear Wheel. The paragraphs below are a photo journey into the replacement of a FL or FXR swing arm. To upgrade the pre 2002 FL, here is a How-To on cheaply replacing the poor parts Harley stuck you with. Now – Let’s Get Er’ Done • Pre- 2002 had weak swing arms and are known to fail. The cleve blocks are the cause of “Rear Steer” or “Rear Fork Deflection”. Harley came up with a patch in 2002, using bearings. Because the pre 2002 transmissions have a 5/8″ mounting hole for the 5/8″ swing arm pivot shaft, a conversion unit has been made. No transmission removal for boring is necessary. Under no circumstances, do I recommend drilling out the transmission case with a hand drill. The drill will “wander” (drift)! • Solution: Go to either a trike shop/manufacturer, e-Bay, or shop and buy a new style swingarm. Harley made an additional upgrade in 2007, try and buy this type 2007 & above). If upgrading to a 2008, Harley use 25mm (smaller than 1″) axles & wheel bearings, you will have to use 25mm bearings. With that said, let’s get on with it. • In the case of a 2007 swingarm; buy and do not pay over $40 for the swing arm and axle. You must use the corresponding axle as a ¾” axle set-up is different (along with wheel bearings & spacers). You positively can not use a pre -2002 HD stock wheel because the wheel bearing spacer will fit into the wheel. Buy 2002 & above style wheels as they (9 spoke) are cheep. • You are going to have to either bore out your stock rear caliper bracket or better still, upgrade your whole rear brake to the new model & sell yours on e-Bay. • I recommend doing the following before hand and have it ready for installation; Remove bearings et al. from the 2002 & later swing arm via press. Bike Work: • Jack up your bike using a center jack. Secure the bike so it will not fall over. You can also use a motorcycle jack. I use a motorcycle dolly

2001 – 2002 GL1800/ GL1800A Rear Tire Inspection

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Filed Under (Honda) by admin on 27-11-2010

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1. Inspect the motorcycle for a punch mark as described in Identification on page 2. If a punch mark is present no further action is necessary, return the unit to the customer. 2. Qualify the unit/customer as follows: •Is the tire on the motorcycle the original factory installed tire? •Is the air pressure loss more than three psi per month? Note: Refer to page 145 in the Owner’s Manual. “Even tires that are in good condition may lose one to two psi per month if not checked and adjusted regularly” . If the GL1800 meets the above qualifications, proceed with the repair procedure. 3. Place the motorcycle on a lift and secure it on the centerstand. 4. Remove the rear wheel as described on page 14-9 of the Service Manual. 5. Starting at the valve stem/balance mark area, carefully remove the rear tire from the wheel. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. 6. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 2001 – 2002 GL1800/GL1800A Rear Tire Inspection GL1800 #6 OCTOBER 2001 MTB 9430 (0109) CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your Honda. These procedures should not be attempted by “do-ityourselfers,” and you should not assume this bulletin applies to your Honda, or that your Honda has the condition described. To determine whether this information applies, contact an authorized Honda dealer. Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800/GL1800A Rear Tire Inspection 0110 GL1800 #6*GL1800 #6*0110*2001-2002 GL1800/GL1800A Rear Tire Inspection*GL1800/GL1800A, Rear Tire Inspection, Bead, Tread*Motorcycle*1800 2 of 4 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #6 OCTOBER 2001 Inside BeadInjury Outside BeadInjury Outside BeadInjury 7. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 8. If there is no evidence of bead damage, re-install the tire on the rim. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Be sure to align the balance dot with the valve stem. Inflate the tire to 41 psi. Install the wheel assembly on the motorcycle and proceed to the Identification and then to the Warranty section. 9. If any damage or injury is present replace the tire and valve stem. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Balance the new tire as necessary

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